That could output 24*120=2880w but I'm abroad where 230v is used and inverter options aren't great so I'm going to use a 24v/1000w inverter. Is wire size based on the battery or the inverter attached to the battery? I will build a 24v system and I have good lithium ion batteries that a friend gave to me which came in this form 60Ah battery paralleled to 120Ah so I'll 7S these into 24v so to 24v/120Ah. I'm confused about wire size as well and constantly second guessing myself. So this is a balance between the cost for larger wire and safety. Keeping in mind that the longer the length the more capacity the wire has to dissipate that heat. High Voltage drops and power loss on each segment of the wire can be a huge problem if the wire length is too long, Longer wire has higher resistance, larger losses, and Higher heating along the wire segment. Then you will realize what the power losses in a system like this are, due to the " I Squared R Losses", and get an understanding, of why wire gauge is so important in a project like this. Use the Volt meter to verify the voltage drop for each length of wire. Use your volt meter and Clamp-on current meter to measure the current and predict the voltage drop across each wire length. For a learning experience after you have this built you could measure the wire lengths and calculate the wire segment resistance. Notice he uses 4 AWG for the PV charge control and 2 AWG for the inverter, this is because the current from the PV charge control is lower amps than the amps required to run the inverter. because it's wasted power and can cause a fire if not done properly.ĪWG American Wire Gauge Diameter and Resistance The voltage drop is E = I X R where E is Voltage drop = Current amps X Resistance. The other thing that is important is the voltage drop from one end of the wire to the other, this includes wires on both sides of the load. You have to look up the wire resistance in a wire table. P = I X I X R where I is the amps flowing and R is the wire resistance. The idea is to reduce this to a minimum value by making the wire resistance as low as possible. You have to know the resistance of the wire and the current flowing to calculate the power. The heat is calculated by the power that is dissipated in the wire. The wire will heat up as current passes through it. It is de-rated by its allowable insulation property. What you need to know is the wire has to be large enough that it won't heat beyond the wire insulation's ability to not break down.
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